Serviceable flex circuit for battery module

Abstract

A battery connector, including a flexible circuit including a first set of electrical circuitry connecting to a plurality of energy storage cells, where the first set of electrical circuitry terminates at a first connection point at the battery connector; a controller including components to control the energy storage cells connected to a second set of electrical circuitry terminating at a second connection point at the battery connector; where the first connection point and the second connection point are electrically connected.

What is claimed is: 
     
       1. A battery connector, comprising:
 a flexible circuit board comprising a first set of wirings connected to a plurality of energy storage cells, wherein the first set of wirings terminates at a first connection point on the flexible circuit board; and 
 a replaceable circuit board comprising:
 a connector that connects to a controller that controls the plurality of energy storage cells; and 
 a second set of wirings electrically connected to the connector and terminating at a second connection point on the replaceable circuit board; 
 
 wherein the first connection point on the flexible circuit board and the second connection point on the replaceable circuit board overlap one another and are electrically connected to each other, 
 wherein the replaceable circuit board further comprises at least one fuse electrically connected between the connector and the second connection point, 
 wherein the first connection point comprises a first solder pad and the second connection point comprises a second solder pad, and wherein the first solder pad and the second solder pad are electrically connected through a soldered connection, 
 wherein the second set of wirings is etched from a conductive foil, wherein the board, and wherein the etched conductive foil is adhered to the polymeric substrate by an adhesive. 
 
     
     
       2. The battery connector of  claim 1 , wherein the first connection point includes a first plurality of solder pads including the first solder pad and the second connection point includes a second plurality of solder pads including the second solder pad, and wherein each solder pad in the first plurality of solder pads is soldered to a respective solder pad in the second plurality of solder pads. 
     
     
       3. The battery connector of  claim 1 , wherein the first connection point includes a first plurality of solder pads, including the first solder pad, wherein the second connection point includes a second plurality of solder pads including the second solder pad, wherein each solder pad in the second plurality of solder pads is connected to the connector through a fuse of the at least one fuse, and wherein each solder pad in the first plurality of solder pads is electrically connected to a respective solder pad in the second plurality of solder pads. 
     
     
       4. The battery connector of  claim 1 , wherein the at least one fuse is rated with an amperage that is lower than an amperage rating of the flexible circuit board. 
     
     
       5. The battery connector of  claim 1 , wherein the first set of wirings comprises voltage sensing wires of the flexible circuit board. 
     
     
       6. The battery connector of  claim 4 , wherein the flexible circuit board is rated for 20 amperes. 
     
     
       7. The battery connector of  claim 6 , wherein each fuse in the at least one fuse is rated for about two amperes. 
     
     
       8. The battery connector of  claim 1 , wherein the at least one fuse is reparable or replaceable by accessing the at least one fuse on the replaceable circuit board. 
     
     
       9. A method, comprising:
 providing a flexible circuit board comprising a first set of wirings in electrical contact with a plurality of energy storage cells, wherein the first set of wirings terminates at a first connection point on the flexible circuit board; 
 positioning a replaceable circuit board comprising a second set of wirings that terminate at a second connection point on the replaceable circuit board in an overlapping relationship with the flexible circuit board, wherein the second set of wirings is electrically connected to a connector that connects to a controller that controls the plurality of energy storage cells; and 
 electrically connecting the first connection point to the second connection point while the flexible circuit board and the replaceable circuit board are in the overlapping relationship, 
 wherein at least one fuse is electrically connected between the second set of wirings and the connector, 
 wherein the electrically connecting includes soldering the first connection point to the second connection point, 
 wherein the second set of wirings is etched from a conductive foil, wherein the etched conductive foil is supported by a polymeric substrate of the replaceable circuit board and wherein the etched conductive foil is adhered to the polymeric substrate by an adhesive. 
 
     
     
       10. The method of  claim 9 , wherein the first connection point includes a first plurality of solder pads and the second connection point includes a second plurality of solder pads, and wherein each solder pad in the first plurality of solder pads is soldered to a respective solder pad in the second plurality of solder pads. 
     
     
       11. The method of  claim 9 , wherein the first connection point includes a first plurality of solder pads, wherein the second connection point includes a second plurality of solder pads, wherein each solder pad in the second plurality of solder pads is connected to the connector through a fuse of the at least one fuse, and wherein each solder pad in the first plurality of solder pads is electrically connected to a respective solder pad in the second plurality of solder pads. 
     
     
       12. The method of  claim 9 , wherein the at least one fuse is rated with an amperage that is lower than an amperage rating of the flexible circuit board. 
     
     
       13. The method of  claim 9 , wherein the first set of wirings comprises voltage sensing wires of the flexible circuit board. 
     
     
       14. The method of  claim 12 , wherein the flexible circuit board is rated for 20 amperes. 
     
     
       15. The method of  claim 14 , wherein each fuse in the at least one fuse is rated for about two amperes. 
     
     
       16. A replaceable electrical connector, comprising:
 a first printed circuit board (PCB); 
 a connector mounted on the first PCB and that connects to a controller that controls energy storage cells of a vehicle; 
 a first set of solder pads on the first PCB; 
 a first set of wirings on the first PCB and electrically connected between the first set of solder pads and the connector; and 
 a set of fuses on the first PCB, each fuse being electrically connected between a respective wiring in the first set of wirings and a respective solder pad in the first set of solder pads, wherein the first set of solder pads are soldered to a second set of solder pads of a second PCB comprising a second set of wirings that are electrically connected to the second set of solder pads and the energy storage cells.